Composite waterproof breathable elastic hats and methodology and dies used to manufacture such hats

ABSTRACT

A composite waterproof breathable elastic hat comprising a knitted outer layer ( 5 ), and/or lining ( 6 ) and a waterproof breathable membrane hood ( 7 ) in which the waterproof breathable membrane hood ( 7 ) is attached to an attachment surface on the outside of the lining ( 6 ) and/or to an attachment surface on the inside of the outer layer ( 5 ). A method of manufacturing a composite waterproof breathable elastic hat and a die ( 8 ) for the manufacture of a composite waterproof breathable elastic hat are also provided.

This invention relates to composite waterproof breathable elastic hats,and methodologies and dies for the manufacture of such hats.

In an outdoor exercise environment protection of the head is extremelyimportant, and the importance of a hat as an accessory goes withoutsaying. However in some severe or extreme outdoor conditions, a normalhat may manage to keep the wearer warm but fail in other specialfunctional requirements for outdoor protection, such as wind-protection,rain protection, snow protection etc. To solve this technical problemcurrent technology generally applies a pre-bonded waterproof andbreathable fabric incorporated by cutting and stitching, as shown inFIGS. 1 and 1A. Waterproof breathable outdoor hats made with thistechnology have seams where the fabric is stitched because of thetechnique used, and can only be made 100% waterproof by adpressing thewaterproof adhesive (label 1) to the seam. Seamless joining is notpossible.

To solve the technical problem of seamless joining, some currenttechnology offers a knitted waterproof breathable hat as shown in FIG.2. The technique uses a previously moulded waterproof breathablemembrane hood (2) which is stitched directly between the knitted hat'sinner layer (3) and outer layer (4), achieving a waterproof effectwithout a seam. However, hats made using this technique can see slippageoccur between the membrane and the knitted inside and outside of thehat, as shown in FIG. 2A, the membrane cannot be completely integratedwith the inside or outside, giving rise to discomfort for the wearer andmakes scratching noises. The wearer experiences extreme discomfort andwearing this hat for certain activities like hunting or military patrolscould have very adverse consequences. Furthermore, because the membranelayer in this hat is slippery it is unable to be elastic and stretchablein all directions, so that the hat is less comfortable to wear thannormal knitted hats.

The technology in the present invention solves the problems in existingtechnology which have been outlined above, whilst producing a protectivehat that has waterproof and breathable properties, as well as preservingcomfort experienced when wearing a normal knitted hat.

According to aspects of the present invention there is provided acomposite waterproof breathable elastic hat comprising a knitted outerlayer, a lining and a waterproof breathable membrane hood, in which thewaterproof breathable membrane hood is attached to an attachment surfaceon the outside of the lining and/or to an attachment surface on theinside of the outer layer.

The lining may be knitted, made of a highly elastic spandex knit or madeof woven cloth cut and stitched.

The outer layer may be made of a highly elastic spandex knit or of wovencloth cut and stitched.

The outer layer may be attached to the lining.

The outer layer may be stitched to the lining.

The outer layer may be stretchable from a relaxed condition to astretched condition.

The lining may be stretchable from a relaxed condition to a stretchedcondition.

Then waterproof breathable membrane hood may have a greater surface areathan either of the outer layer and lining when said outer layer andlining are in the relaxed condition.

The waterproof breathable membrane hood may be non-elastic orsubstantially non-elastic.

The waterproof breathable membrane hood may be attached to the liningand/or outer layer at a plurality of spaced locations.

The waterproof breathable membrane hood may be attached to the liningand/or outer layer at a plurality of substantially uniformly spacedlocations.

The waterproof breathable membrane hood may be adhered to the liningand/or outer layer at a plurality of spaced locations over theattachment surface of one or both of the lining and outer layer.

The lining and/or outer layer may be adhered with one or more of TPU[thermoplastic polyurethane], PES [polyester] and PA [polyamide, nylon].

The hat may be stretchable from a resting condition in which the outerlayer and lining are in their relaxed condition and the waterproofbreathable membrane hood has a wrinkle, puckered or generally corrugatedconformation between the outer layer and the lining, and an extendedcondition in which the outer layer and lining are in their stretchedcondition and the waterproof breathable membrane hood is in a flat orless wrinkled, less puckered or less corrugated conformation.

The waterproof breathable membrane hood may have a bi-directionalwrinkled or corrugated conformation, such that it is wrinkled, puckeredor corrugated generally in both the longitudinal and circumferentialdirections, when the hat is in the resting condition, from which thewaterproof breathable membrane hood can move with the outer layer andlining when the outer layer and lining are extended to their stretchedconditions as the hat is taken from its resting condition, to give thehat two way stretch characteristics.

The waterproof breathable membrane hood may comprise bonded layerspressed together using a high temperature sealing machine or a highfrequency plastic bonding machine or high frequency welding.

According to further aspects of the present invention there is provideda method of manufacturing a composite waterproof breathable elastic hat,the method comprising stretching a lining or outer layer over a die ormould, positioning a waterproof breathable membrane hood over the liningor outer layer and stretching an outer layer or lining over thewaterproof breathable membrane hood, attaching the lining and/or theouter layer to the waterproof breathable membrane hood to form a hatstructure which upon removal from the die or mould contracts until thelining and/or layer are in a relaxed condition and the waterproofbreathable membrane hood is located therebetween in a wrinkled, puckeredor corrugated conformation.

According to yet further aspects of the present invention there isprovided a method of manufacturing a composite waterproof, breathableelastic hat, the method comprising stretching a lining or outer layerover a die or mould, positioning a waterproof breathable membrane hoodover the lining or outer layer, attaching the lining or outer layer tothe waterproof breathable membrane hood to form a bi-layer, which uponremoval from the die or mould contracts until the lining or outer layeris in a relaxed condition and the waterproof breathable membrane hood isattached to the lining in a wrinkled, puckered or corrugatedconformation.

The membrane hood may be positioned over the lining or outer layer in arelaxed, non-stretched condition.

Adhesive may be applied to the lining and/or outer layer and/orwaterproof breathable membrane hood at discrete, spaced locations.

The adhesive may be applied prior to locating the waterproof breathablemembrane hood and/or the lining and/or the outer layer over the die.

The adhesive may be spotted, dusted and/or taped on the respective oneor more of lining, outer layer and/or waterproof breathable membranehood.

The adhesive may be melted or softened on the die to adhere thewaterproof breathable membrane hood and the lining and/or outer layertogether.

The other of a lining or outer layer may be positioned over the bi-layerto form a hat structure. The hat structure may be stitched along or nearits edge to form a hat.

According to further aspects of the present invention there is provideda hat structure for a composite waterproof breathable hat, the structurecomprising an elastic outer layer or elastic lining and a non-elastic orsubstantially non-elastic breathable membrane hood attached to anattachment surface on the lining or outer layer.

The waterproof breathable membrane hood may be attached to the lining orouter layer as described above.

According to still further aspects of the present invention there isprovided a die or mould for the manufacture of a composite waterproofbreathable elastic hat and/or has structure defined in any of thepreceding twenty-six paragraphs, in which the die comprises a formingsurface on which the hat or hat structure is formed, the forming surfacebeing arranged and dimensioned to receive and form the waterproofbreathable membrane hood in its relaxed condition.

The die may comprise a flat-plate die with the same flat dimensions asthe waterproof breathable membrane hood.

According to further aspects of the present invention there is provideda compound waterproof breathable elastic knitted hat, the hat has aknitted outer layer and lining along with a waterproof breathablemembrane hood, characterized in that the waterproof breathable membranehood referred to, is attached by use of a compound die to the outside ofthe hat lining (the attachment surface) and/or to the inside of theouter layer (the attachment surface), forming a multi-function sandwichlayer.

Further, the hat's lining described is knitted, or cut and stitched fromhighly elastic spandex knit or woven cloth.

Further, the hat's outer layer described is knitted, and may be stitchedto the inner layer to form one piece.

Further, the waterproof breathable membrane hood as described is firstpressed together using a high temperature sealing machine or by a highfrequency plastic bonding machine.

Further, the dimensions of the waterproof breathable membrane hood asdescribed, when extended are larger than the flat dimensions of theouter layer and/or lining which are attached to it to form amulti-function sandwich layer.

Further, the adhesive used to attach the multi-function sandwich layeras described is TPU, PES or PA melt adhesive.

Further, the melt adhesion as described employs melt adhesion technologywith an off-set point arrangement or dusting, with prior preparatoryapplication to the attachment surface of the waterproof breathablemembrane cap as described or to the attachment surface(s) of the outerlayer or lining of the hat which makes up the multi-function sandwichlayer.

Further, after the multi-function sandwich layer as described has beenadhered and then removed from the compound die as described, themembrane of the waterproof breathable hood as described takes on abi-directional corrugated structure (walnut wrinkling), with the resultthat the membrane layer as described acquires the characteristics ofbeing able to be stretched in any direction along with the elasticmaterial to which it has been attached.

This invention also introduces a die for the manufacture of the compoundwaterproof breathable elastic knitted hat as described, characterized inthat the compound die used to make a multi-function sandwich layer asdescribed is a flat-plate die with the same flat dimensions as thewaterproof breathable membrane hood as described.

This invention also introduces a process for making the compoundwaterproof breathable elastic knitted hat as described, characterized inthat:

Step 1, the hat lining and/or external layer to be attached are placedon a compound die as described;

Step 2, the waterproof breathable membrane hood described is slipped ontop, and the hood is brought in contact with the hot melt adhesivepoints or dusting applied in preparation;

Step 3, the hat lining to be attached and/or the outer layer is adheredby a hot press, forming a multi-function sandwich layer;

Step 4, the multi-function sandwich layer as described and the parts ofthe hat which have not been adhered are stitched together along edges ofthe hat as described, forming a complete hat.

The present invention will now be described by way of example only, withreference to the accompanying drawings, in which:

FIG. 1 is a diagram of a waterproof hat cut and stitched using currenttechnology;

FIG. 1A is the seam of the cut and stitched waterproof hat as shown inFIG. 1;

FIG. 2 is a diagram of a waterproof knitted hat using current technologyin which a waterproof hood is inserted by stitching;

FIG. 2A is a cross-section of the waterproof breathable hood between thelining and outer layer of the waterproof knitted hat, as shown in FIG.2;

FIG. 3 is a diagram of how the present invention uses heat sealingtechnology to make a multi-function sandwich layer;

FIG. 3A is a cross-section of the waterproof breathable hood between thelining and outer layer of the waterproof knitted hat, as shown in FIG.3;

FIGS. 4A-4C is a structure diagram of the off-set hot melt adhesivepoint sealing technology used in the present invention;

FIG. 4A is the structure before sticking of the waterproof hood as shownalong with the lining stretched and then slipped over a compound die;

FIG. 4B is the structure after the adhesion of the waterproof hood asshown along with the hat lining stretched and then slipped over acompound die;

FIG. 4C is a structure diagram of the waterproof hood and the hat liningafter they have been adhered and removed from the die, producingcorrugations.

1 Line of the seamed waterproof hat where waterproofing is adpressed

2 Waterproof hood using current technology

3 Hat lining using current technology

4 Hat outer layer using current technology

5 Hat outer layer using this invention

6 Hat lining using this invention

7 Waterproof hood using this invention with prior application of hotmelt adhesive points

8 Compound die used with this invention

The present invention provides a composite waterproof breathable elastichat comprising a knitted outer layer 5, a lining 6 and a waterproofbreathable membrane hood 7 in which the waterproof breathable membranehood 7 is attached to an attachment surface on the outside of the lining6 and/or to an attachment surface on the inside of the outer layer 5such as to form a hat structure.

In more detail, the lining 6 is knitted, made of a highly elasticspandex knit or made of woven cloth cut and stitched. The outer layer 5is typically made of a highly elastic spandex knit or of woven cloth cutand stitched.

In certain embodiments the outer layer 5 is attached to the lining 6 andis typically stitched to the lining 6.

The outer layer 5 is stretchable from a relaxed condition to a stretchedcondition. Similarly the lining 6 is stretchable from a relaxedcondition to a stretched condition. The waterproof breathable membranehood 7 has a greater surface area than either of the outer layer 5 orthe lining 6 when the outer layer 5 and lining 6 are in their relaxedcondition and the waterproof breathable hood is non-elastic orsubstantially non-elastic (non-stretchable).

The waterproof breathable membrane hood 7 is attached to one or both ofthe lining 6 and outer layer 5 at a plurality of spaced locations, whichspaced locations can be uniformly or generally uniformly spaced.

The waterproof breathable membrane hood 7 is adhered to the lining 6and/or outer layer 5 at a plurality of spaced locations over theattachment surface of one or both of the lining 6 and outer layer 5.

A thermosetting adhesive including one or more of a thermoplasticpolyurethane, (TPU), polyester (PES) and/or polyamide (PA) can be used.

The hat structure can be secured by stitching typically along or nearthe edge thereof to form a hat.

The hat is stretchable from a resting condition in which the outer layer5 and the lining 6 are in their relaxed condition and the waterproofbreathable membrane hood has a wrinkled or generally corrugated orpuckered conformation between the outer layer 5 and the lining 6, and anextended condition in which the outer layer 5 and lining 6 are in theirrespective stretched condition and the waterproof breathable membranehood 7 is in a flat or less wrinkled or less puckered or less corrugatedconformation.

When the hat is in its resting condition the waterproof breathablemembrane hood 7 has a bi-directional wrinkled, puckered or corrugatedconformation so that when the hat is stretched from the restingcondition, such as to be worn on the head of a user, the waterproofbreathable membrane 7 can move or expand (even though it is notinherently stretchable) with the outer layer and lining, by theflattening of the wrinkles or corrugations, allowing the hat to stretchwhilst retaining its waterproof characteristics.

Attaching one or both of the lining 6 and outer layer 5 to thewaterproof breathable membrane hood helps to ensure controlled movementof the membrane hood within the lining and outer layer.

The location of the waterproof breathable membrane hood 7 between thelining 6 and the outer layer 5 typically means that its wrinkled orcorrugated conformation is not apparent from a visual inspection of theoutside of the hat, giving the hat a typical or traditional visualappearance.

In addition to the conformation of the waterproof breathable membranehood allowing the hood 7 to expand as the outer layer 5 and lining 6 arestretched, its conformation and attachment also enable it to remainexpanded when the hat is being worn by a user, thus rendering the hatcomfortable when being worn and waterproof and heat insulating in use.

The waterproof breathable membrane hood can comprise bonded layerspressed together using a high temperature sealing machine or a highfrequency plastic bonding machine (welder).

The present invention also provides a method of manufacturing acomposite breathable elastic hat in which one of a lining 6 or outerlayer 5 of the hat is stretched over a die 8, mould or former, awaterproof breathable membrane hood 7 is then positioned over the lining6 or outer layer 5 and another of an outer layer 5 or lining 6 isstretched over the waterproof breathable membrane hood 7. The lining 6and/or the outer layer 5 are attached to the waterproof breathablemembrane hood 7 to form a hat structure or laminate structure which onremoval from the die, mould or former contracts until the lining 6 andouter layer 5 are in a relaxed condition and the waterproof breathablemembrane hood 7 is located therebetween in a wrinkled, puckered orcorrugated conformation.

The waterproof breathable membrane hood 7 is positioned over the lining6 in a relaxed, non-stretched condition and adhesive is applied to oneor more of the lining 6, outer layer 5 and waterproof breathablemembrane hood 7 at discrete spaced locations, typically prior tolayering. The adhesive can be applied by spotting, dusting, taping orother suitable means to provide discrete, spaced areas of adhesive onthe respective lining 6, outer layer 5 and/or waterproof breathablemembrane hood 7, to provide for attachment of at least one of the lining6 and outer layer 5 to the waterproof breathable membrane hood 7. Incertain embodiments adhesive is added so that both the lining 6 and theouter layer 5 are each adhered to the waterproof breathable membranehood 7.

The adhesive may be a thermoset adhesive that is melted or softened onthe die to adhere to the lining 6 and/or waterproof breathable membranehood 7 and/or outer layer 5 together. The multifunction sandwich layermay be stitched to hold the multifunction sandwich layer together.

The invention further provides a composite waterproof breathable elastichat, and a method of manufacturing such a hat in which a bi-layer isfirst formed of a lining or outer layer attached to a waterproofbreathable membrane hood. The lining or outer layer is elastic orstretchy whereas the waterproof breathable membrane hood is non-elasticor substantially non-elastic.

The lining or outer layer in such bi-layers are attached to thewaterproof breathable membrane in the same or similar manner discussedabove so that when the bi-layer is removed from a mould or die thebi-layer contracts until the lining or outer layer is in a relaxedcondition and the waterproof breathable membrane hood is attached to thelining in a wrinkled, puckered or corrugated conformation.

To form a hat from the bi-layer the other of an outer layer or lining isattached to the bi-layer off the die, so in the case where the bi-layeris formed of a lining (relaxed) and a waterproof breathable membranehood in its relaxed condition then an outer layer is secured to theother side of the membrane hood to form a three layer lining. In suchembodiments the lining, waterproof breathable membrane hood and outerlayer are secured together generally by stitching through the lining andouter layer typically along the edge or edges over the lining to form ahat. The stitching may or may not extend through the waterproofbreathable membrane, but in embodiments where it does, this is typicallyin areas where any detriment to the waterproof nature of the hat is ofno practical detriment.

It will of course be appreciated that in those embodiments where thebi-layer comprises an outer layer and a waterproof breathable membrane,then a lining is attached to form the hat structure, with the waterproofbreathable membrane between the lining and the outer layer.

The invention also provides a hat structure for a composite waterproofbreathable hat or from which a composite waterproof breathable hat canbe made. The hat structure comprises an elastic outer layer or elasticlining and a non-elastic or substantially non-elastic waterproofbreathable membrane hood attached to an attachment surface of the liningor outer layer.

The waterproof breathable membrane hood may be attached to the lining orouter layer as described above.

The invention also provides a die, mould or former 8 for the manufactureof a composite waterproof breathable elastic hat or hat structure asdescribed above, in which the die 8 comprises a forming surface on whichthe hat or hat structure is formed, the forming surface being arrangedand dimensioned to receive and form the waterproof breathable membranehood in its relaxed condition.

The die comprises a flat plate die with the same flat dimensions as thewaterproof breathable membrane hood 7.

The following are specific examples of the invention's implementation:

A waterproof breathable elastic knitted hat as shown in FIG. 3,including a knitted outer layer (5), knitted or elastic fabric lining(6), and a waterproof breathable membrane hood (7). This waterproofbreathable membrane hood (7) is attached to the exterior of the hatlining (6) using a compound die (8), so that the waterproof breathablemembrane hood (7) and the hat lining (6) form a single complex structureserving as a multi-function sandwich layer inserted between the liningand outer layers of the hat. The outcome is that without any loss ofbeauty in appearance or comfort in use the hat as described is renderedcompletely seamless and breathable and is wind and water proof.

Another example of the invention's implementation:

A waterproof breathable elastic knitted hat as shown in FIG. 3,including a knitted outer layer (5), a knitted or elastic fabric lining(6), and a waterproof breathable membrane hood (7). This waterproofbreathable membrane hood (7) is attached to the inner surface of thehat's outer layer (5) using a compound die (8), so that the waterproofbreathable membrane hood (7) and the hat's outer layer (5) forms asingle complex structure serving as a multi-function sandwich layerinserted between the inner (lining) and outer layers of the hat. Theoutcome is that without any loss of beauty in appearance or comfort inuse the hat as described is rendered completely seamless and breathableand is wind and water proof.

Another example of the invention's implementation:

A waterproof breathable elastic knitted hat as shown in FIG. 3,including a knitted outer layer (5), a knitted or elastic fabric lining(6), and a waterproof breathable membrane hood (7). This waterproofbreathable membrane hood (7) is attached to the outside surface of thehat's lining (6) and the inner surface of the hat's outside layer (5)using a compound die (8), so that the waterproof breathable membranehood (7) and the hat's lining (6) and hat's outer layer (5) togetherform a hat with a complex structure.

A specific example of the implementation of the compound die introducedby this invention for the processing of a compound waterproof breathableelastic knitted hat:

As shown in FIGS. 4A-4C the waterproof breathable membrane hood (7)which forms the multifunction sandwich layer for the waterproof elasticknitted hat has the same dimensions as the compound die plate (8), whilebeing bigger than the flat dimensions of the hat's lining (6) to whichit is attached.

An example of the processing method introduced in this invention to makea compound waterproof breathable elastic knitted hat:

As shown in FIGS. 3 and 4A-4C, the hat's lining (6), after stretching toa structure like FIG. 4A, is slipped over the compound die (8), andafter being attached to the hood (7) by hot pressure takes on astructure like FIG. 4B. When the hat is removed from the compound die(8), the elastic hat lining (6) shrinks back, and causes the compoundsandwich layer to shrink back to a structure like FIG. 4C, the resultbeing that the slightly larger waterproof breathable membrane hood (7)takes on a crinkled wrinkled (which can also be described as puckered orcorrugated) structure, in its natural state. This gives it the propertyof being stretchable in all directions, so that when worn on the head itis comfortably elastic.

To sum up, this invention introduces a compound waterproof breathableelastic hat and the die and process used to make it. The hat has anouter layer and a lining with elastic properties and a waterproofbreathable membrane hood. This hood is attached to the exterior of thehat's lining and/or the interior of the hat outer layer with the use ofa compound die, and in consequence the hood is combined into a singlestructure with at least the hat's lining or the hat's exterior layer. Asa result, it has no ill effects on the hat's beauty of appearance orcomfort in use, the hat is made seamless, windproof, waterproof andbreathable, and the hood is given all-round elasticity without slippingand without noise.

Although the examples of implementation given above show some technicalpossibilities they should not be taken to limit this invention's scopeof protection. Ordinary technicians in this field can improve and makechanges to the implementation described without violating the essenceand scope of the invention.

What is claimed is:
 1. A composite waterproof breathable elastic hatcomprising a knitted outer layer, a lining and a waterproof breathablemembrane hood, in which the waterproof breathable membrane hood isattached to an attachment surface on the outside of the lining and/or toan attachment surface on the inside of the outer layer.
 2. A compositewaterproof breathable elastic hat as claimed in claim 1, in which thelining is knitted, made of a highly elastic spandex knit or made ofwoven cloth cut and stitched.
 3. A composite waterproof breathableelastic hat as claimed in claim 1, in which the outer layer is made of ahighly elastic spandex knit or of woven cloth cut and stitched.
 4. Acomposite waterproof breathable elastic hat as claimed in claim 1, inwhich the outer layer is attached to the lining.
 5. A compositewaterproof breathable elastic hat as claimed in claim 4, in which theouter layer is stitched to the lining.
 6. A composite waterproofbreathable elastic hat as claimed in claim 1, in which the outer layeris stretchable from a relaxed condition to a stretched condition.
 7. Acomposite waterproof breathable elastic hat as claimed in claim 6, inwhich the lining is stretchable from a relaxed condition to a stretchedcondition.
 8. A composite waterproof breathable elastic hat as claimedin claim 7, in which the waterproof breathable membrane hood has agreater surface area than either of the outer layer and lining when saidouter layer and lining are in their relaxed condition.
 9. A compositewaterproof breathable elastic hat as claimed in claim 8, in which thewaterproof breathable membrane hood is non-elastic or substantiallynon-elastic.
 10. A composite waterproof breathable elastic hat accordingto claim 1, in which the waterproof breathable membrane hood is attachedto the lining and/or the outer layer at a plurality of spaced locations.11. A composite waterproof breathable elastic hat as claimed in claim10, in which the waterproof breathable membrane hood is attached to thelining and/or outer layer at a plurality of substantially uniformlyspaced locations.
 12. A composite waterproof breathable elastic hat asclaimed in claim 10, in which the waterproof breathable membrane hood isadhered to the lining and/or outer layer at a plurality of spacedlocations over the attachment surface of one or both of the lining andouter layer.
 13. A composite waterproof breathable elastic hat asclaimed in claim 12, in which the lining and/or outer layer is adheredwith one or more of TPU [thermoplastic polyurethane], PES [polyester]and PA [polyamide, nylon].
 14. A composite waterproof breathable elastichat according to claim 8, in which the hat is stretchable from a restingcondition in which, the outer layer and lining are in their relaxedcondition and the waterproof breathable membrane hood has a wrinkled orgenerally corrugated conformation between the outer layer and thelining, and an extended condition in which the outer layer and liningare in their stretched condition and the waterproof breathable membranehood is in a flat or less-wrinkled or less-corrugated conformation. 15.A composite waterproof breathable elastic hat as claimed in claim 14, inwhich the waterproof breathable membrane hood has a bi-directionalwrinkled or corrugated conformation when the hat is in the restingcondition, from which the waterproof breathable membrane hood can movewith the outer layer and lining when the outer layer and lining areextended to their stretched conditions as the hat is taken from itsresting condition.
 16. A composite waterproof breathable elastic hat asclaimed in claim 1, in which the waterproof breathable membrane hoodcomprises bonded layers pressed together using a high temperaturesealing machine or a high frequency plastic bonding machine.
 17. Amethod of manufacturing a composite waterproof breathable elastic hat,the method comprising stretching a lining or outer layer over a die,positioning a waterproof breathable membrane hood over the lining orouter layer and stretching an outer layer or lining over the waterproofbreathable membrane hood, attaching the lining and/or outer layer to thewaterproof breathable membrane hood to form a hat structure which uponremoval from the die contracts until the lining and outer layer are in arelaxed condition and the waterproof breathable membrane hood is locatedtherebetween in a wrinkled or corrugated conformation.
 18. A method ofmanufacturing a composite waterproof, breathable elastic hat, the methodcomprising stretching a lining or outer layer over a die or mould,positioning a waterproof breathable membrane hood over the lining orouter layer, attaching the lining or outer layer to the waterproofbreathable membrane hood to form a bi-layer, which upon removal from thedie or mould contracts until the lining or outer layer is in a relaxedcondition and the waterproof breathable membrane hood is attached to thelining in a wrinkled, puckered or corrugated conformation.
 19. A methodas claimed in claim 17, in which the waterproof breathable membrane hoodis positioned over the lining or outer layer in a relaxed, non-stretchedcondition.
 20. A method as claimed in claim 17, in which adhesive isapplied to the lining and/or outer layer and/or waterproof breathablemembrane hood at discrete, spaced locations.
 21. A method as claimed inclaim 20 in which the adhesive is applied prior to layering thewaterproof breathable membrane hood and/or the lining and/or outer layerover the die.
 22. A method as claimed in claim 20, in which the adhesiveis spotted, dusted and/or taped on the respective one or more of lining,outer layer and/or waterproof breathable membrane hood.
 23. A method asclaimed in claim 20, in which the adhesive is melted or softened on thedie to adhere the waterproof breathable membrane hood and/or the liningand/or outer layer together.
 24. A method as claimed in claim 18, inwhich the other of an outer layer or lining is positioned over thebi-layer to form a hat structure.
 25. A method as claimed in claim 17,in which the hat structure is stitched along or near its edge to form ahat.
 26. A hat structure for a composite waterproof breathable hat, thestructure comprising an elastic outer layer or elastic lining and anon-elastic or substantially non-elastic breathable membrane hoodattached to an attachment surface on the lining or outer layer.
 27. Adie for the manufacture of a composite waterproof breathable elastic hatas claimed in claim 1, in which the die comprises a forming surface onwhich the hat or hat structure is formed, the forming surface beingarranged and dimensioned to receive and form the waterproof breathablemembrane hood in its relaxed condition.
 28. A die as claimed in claim27, in which the die comprises a flat-plate die with the same flatdimensions as the waterproof breathable membrane hood.